Wall box fill and patch system and method

ABSTRACT

A hole patch system having a front portion including an adhesive rear face and a closed cell foam backer attached to the rear face of the front portion. The foam backer can be inserted into a hole and secured in place via the front portion which adheres to the surface of the structure surrounding the hole. A primary purpose is to fill abandoned wall boxes, such that the foam backer is preformed to fit the standard shape and size of wall boxes. However, holes of any shape or size could be filled using variations of the present invention.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority in U.S. Provisional Pat. Application No. 63/331,631 Filed Apr. 15, 2022, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to a wall patch system and method for use thereof, and more specifically to a fill and patch system for abandoned wall boxes and holes in surfaces, such as walls and ceilings made of drywall, plaster, or other typical constructed surfaces.

2. Description of the Related Art

When remodeling a home or office, wall boxes which previously may have contained electrical outlets, phone outlets, or light switches may be abandoned. Typically, these would be removed and the wall would be patched using one of three typical methods. Other holes in walls and ceilings, caused for various reasons, are similarly patched.

The first such method uses a cut piece of drywall material where a portion has been removed from the paper backing. This paper backing can be used to produce a seamless interface between the surrounding wall and the hole that is being patched. However, this paper requires a separated adhesive, can be time-consuming, and is not likely to provide a smooth and unnoticeable patch. These jobs typically require craftsmen with industry expertise to perform correctly.

The second typical method is to apply adhesive flat plates over the abandoned wall box opening. Drywall mud is then placed into the opening, which oozes into gaps causing a depression. This requires a thicker drywall mud to be used which requires a longer dry time and often causes cracking. It also makes the area more difficult to make smooth and unnoticeable.

The third such method removes the abandoned box and replaces it with a wooden backer. The wall can then be patched with a piece of drywall material similar to the first method, and the area can be taped and mudded to seal it.

What is needed and desired is a single patch kit which can adhere to the surrounding drywall while filling and gripping the hole and/or abandoned wall box, not requiring the box to be removed, and which can then be mudded over to provide a solid flat patch.

Heretofore there has not been available a system or method for a wall box patch with the advantages and features of the present invention.

BRIEF SUMMARY OF THE INVENTION

The present invention generally provides a patch system for an abandoned wall box, such as an abandoned outlet box, phone jack box, light switch box, or any other holes in wall or ceiling surfaces. The system includes a patch device which has an adhesive drywall tape mesh front face connected to a closed cell foam backer. An overhang of the drywall tape allows the backer to fill the abandoned wall box while the overhang seals and secures the backer within the opening while securing itself against the surrounding wall material. This entire device is sold in a unitary construction and requires no on-site construction. Once placed within the abandoned wall box, the drywall tape can be mudded over to provide a smooth flat wall surface. The foam backer fills and grips the interior space of the abandoned box.

An embodiment of the present invention could also be used to patch holes of other shapes and sizes. The closed cell foam backer could be shaped manually or during manufacturing to fit into round holes or holes of virtually any shape with or without the presence of an abandoned wall box.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.

FIG. 1 is a three-dimensional isometric view of a preferred embodiment of the present invention shown from a rear view.

FIG. 2 is a three-dimensional isometric view thereof shown from a front view.

FIG. 3 is a three-dimensional isometric view thereof shown in a typical environment of a wall with an abandoned wall box.

FIG. 4 is a three-dimensional isometric view thereof shown installed within the abandoned wall box thereof.

FIG. 5 is a three-dimensional isometric view thereof showing a covering of the present invention once installed.

FIG. 6 is a three-dimensional isometric view of an alternative embodiment of the present invention shown from a rear view.

FIG. 7 is a three-dimensional isometric view of thereof shown from a front view.

FIG. 8 is a three-dimensional isometric view thereof shown in a typical environment of a surface with a hole.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS I. Introduction and Environment

As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.

Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

II. Preferred Embodiment Abandoned Wall Box Patch System 2

As shown in FIG. 1 , the present invention provides a wall box patch system 2 which has a front portion 4 which is made of an adhesive drywall tape, typically a mesh or paper, and a back portion 6 which is made of a closed cell foam or a similar material which can expand and fill a space within an abandoned wall box. The mesh may have openings 14. The back portion 6 can be cut or reformed if necessary, but the shape and size is designed to fit a hole left by a typical wall box.

FIG. 2 shows the wall box patch system 2 from the front side.

FIG. 3 shows how the opening 10 within a wall 8 containing an abandoned wall box 12 can be filled with the wall box patch system 2. The wall box 12 itself may actually be removed prior to filling if desired or may be left in place. FIG. 4 shows the present wall box patch system 2 installed within the opening 10, and FIG. 5 shows the wall box patch system 2 being covered by a covering 16, which may include drywall mud, spackle, and/or paint.

III. Alternative Embodiment Hole Patch System 102

While the previous embodiment is designed to fit into a hole formed from a standard abandoned wall box which has a generally uniform shape and size, other holes could also be filled with variations of the present invention. FIGS. 6 - 8 show a slightly alternative hole patch system 102 having a front portion 104 and rear portion 106 as above. The rear portion 106 here is shaped in a circular or cylinder shape for fitting into a hole 110 that may be formed by a standard hole saw bit, such as used for placing vents or piping through walls or structures. The same backing 114 is included in the front portion 104, optionally including mesh as above. The foam forming the rear portion 106 could be formed to any shape and size to fit any hole, however standard hole saw sizes can be preemptively made to limit the amount of on-site manipulation required. The hole 110 may include a box 112, such as a round light box, or may simply be a hole through a wall, ceiling, or other structure.

Any hole in a wall or structure could be cut around and out to fit the size of the rear portion 106 of the patch system 102. Smaller holes can simply be sawed or cut around. Larger holes may require larger patch systems.

It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects. 

Having thus described the invention what is claimed as new and desired to be secured by letters patent is:
 1. A hole patch system comprising: a patch having a front portion having a front face and a rear face having a front-portion area; said rear face of said front portion comprising an adhesive material; a rear portion affixed to said rear face of said front portion via said adhesive material, wherein; said rear portion comprising a closed cell foam having a rear-portion area smaller than the area of said rear face of said front portion such that edges of said front portion overhang edges of said rear portion; said rear portion configured to be inserted into a hole in a structure such that said rear portion fills said hole; and said front portion configured to seal about said rear portion within said hole.
 2. The system of claim 1, further comprising: wherein said hole comprises an abandoned wall box; and said back portion shaped and sized to fit within said abandoned wall box.
 3. The system of claim 1, further comprising: wherein said hole is formed by a circular hole saw; and said back portion shaped and sized to fit within said hole.
 4. The system of claim 1, further comprising: said front face of said front portion configured to receive a covering material, thereby further sealing said hole.
 5. The system of claim 1, wherein said covering material is a material selected from the list comprising: spackle; drywall mud; all putty; and paint.
 6. A method of patching a hole, the method comprising the steps: providing a hole patch element having a front portion and a rear portion, wherein said front portion comprises a front face and a rear face having a front-portion area, and wherein said rear portion comprises a closed cell foam having a rear-portion area smaller than the area of said rear face of said front portion such that edges of said front portion overhang edges of said rear portion; affixing said rear portion to said rear face of said front portion via said adhesive material; placing said rear portion with the hole; securing said rear portion within the hole by placing said rear face of said front portion against a surface surrounding said hole and securing said rear face against said surface via said adhesive material; and thereby filling and patching said hole.
 7. The method of claim 6, wherein said hole comprises an abandoned wall box and said back portion is shaped and sized to fit said abandoned wall box.
 8. The method of claim 6, wherein said hole is formed from a circular hole saw and said back portion is shaped and sized to fit a circular hole. 